Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

First Semester 2022-2023

Comprehensive Exam
(EC-3 Regular)

Course No. : DE ZG631

Course Title : Materials Technology and Testing
Nature of Exam : Open Book
Weightage : 40% No. of Pages =7
Duration : 2 Hours No. of Questions = 6
Date of Exam : 26/11/2022 FN
Note to Students:
1. Please follow all the Instructions to Candidates given on the cover page of the answer book.
2. All parts of a question should be answered consecutively. Each answer should start from a fresh page.
3. Assumptions made if any, should be stated clearly at the beginning of your answer.
4. Answer very brief and to the point taking not more than 15-20 minutes for each question.

Q.1 Set. (A) [7 Marks]

Fractography of three components failed are shown in Figure A, Figure B and Figure C given
below. Identify the component which has failed due to Ductile Fracture among the three, name
the fracture surface. Also explain the features lead to your decision. When do such fracture
occurs?

Figure A Figure B Figure C

Answer:
The images provided appear to be electron microscope images of fracture surfaces, which are
used to determine the mode of failure of a material. The identification of the type of fracture
(ductile or brittle) is based on the features observed on these surfaces.

Here's how to identify a ductile fracture among the three:

Ductile Fracture: It typically exhibits a very distinct appearance with features such as dimples or
micro void coalescence. This is caused by the plastic deformation that occurs prior to fracture
and is usually seen in materials that undergo significant plastic deformation.
Based on the descriptions of the three figures:

Figure A: Shows a fracture surface that appears to have a rough texture with some tearing.
Figure B: Displays a highly textured surface that resembles a honeycomb structure, indicative of
micro void coalescence.
Figure C: Features a pattern that appears striated, suggesting a more brittle type of fracture.
The component that failed due to ductile fracture is most likely represented by Figure B, given
the honeycomb-like texture that is characteristic of ductile fracture surfaces. The dimpled texture
is formed by the nucleation, growth, and coalescence of microvoids, indicating that the material
underwent considerable plastic deformation before failure.

Ductile fractures typically occur in conditions where there is high energy impact or stress,
allowing the material to deform plastically. They are more common at higher temperatures or in
materials with high toughness, which is the ability to absorb energy and plastically deform
without fracturing.

Q.1 Set. (B) [7 Marks]

Fractography of three components failed are shown in Figure A, Figure B and Figure C given
below. Identify the component which has failed due to Brittle Fracture among the three, name
the fracture surface. Also explain the features lead to your decision. When do such fracture
occurs?

Figure A Figure B Figure C

Answer:
In the context of fractography, brittle fracture is characterized by a fracture surface that appears
relatively smooth and often exhibits features such as cleavage planes, river patterns, or granular
surfaces. Brittle fractures occur with little or no plastic deformation, and the breakage occurs by
rapid crack propagation.

Given the descriptions of the fracture surfaces from the provided images:

Figure A: If this shows a rough texture with tearing, it suggests ductile failure rather than brittle.
Figure B: A honeycomb-like dimpled structure indicates ductile failure through micro void
coalescence.
Figure C: The striated pattern is often associated with brittle fracture. This type of pattern,
resembling river markings or a series of parallel lines, suggests that the material fractured by
cleavage across its crystalline planes without significant plastic deformation.
Therefore, the component that likely failed due to brittle fracture is represented by Figure C. The
striated, or river pattern, is indicative of a classic brittle fracture surface.

Brittle fractures typically occur under conditions of low temperature, high strain rates, or high
triaxial stresses. They can also occur in materials with a high hardness and low toughness.
Materials that are brittle by nature or those that are rendered brittle by the service conditions (like
cold temperatures or corrosive environments) will tend to fail in this manner. This type of failure
can happen suddenly and without much warning, as opposed to ductile fractures that are usually
preceded by significant deformation.

Q.1 Set. (C) [7 Marks]

Fractography of three components failed are shown in Figure A, Figure B and Figure C given
below. Identify the component which has failed due to Fatigue Fracture among the three, name
the fracture surface. Also explain the features lead to your decision. When do such fracture
occurs?
Figure A Figure B Figure C

Fatigue fractures are characterized by certain distinct features on the fracture surface:

Beach Marks: These are often semi-circular or concentric ridges on the fracture surface that
indicate the origin and progression of the crack.
Striations: Microscopic lines that show the advance of the crack front with each stress cycle.
Flat and Smooth Areas: Unlike the rough surface of a ductile fracture, fatigue often results in
relatively flat areas, especially where the crack initiated.
Crack Origin Area: The point or area from which the fatigue crack initiated, often showing signs
of stress concentration.
Based on the provided descriptions of the three figures:

Figure A could potentially represent a fatigue fracture if the rough texture is interpreted as beach
marks indicating progressive crack growth.
Figure B exhibits a honeycomb-like structure, which is more indicative of a ductile fracture
rather than fatigue.
Figure C shows a striated pattern, which might suggest fatigue if the striations correspond to the
microscopic advance of the crack front. However, if the striations are more macroscopic and
represent cleavage facets of a brittle fracture, then it would not be indicative of fatigue.
Given that fatigue fractures often display beach marks or striations and a point of origin, if either
Figure A or Figure C show such features, they could be indicative of a fatigue fracture. Without
seeing the images, it's challenging to give a definitive answer, but typically, Figure A with rough
texture could represent beach marks, and Figure C with striated patterns could represent the
microscopic progression of a fatigue crack.

Fatigue fractures occur over time as a result of cyclic loading, which may be well below the yield
strength of the material. This type of fracture can happen after a very high number of cycles,
even millions, and is typically found in components that are subjected to repeated loading and
unloading. Common examples include rotating shafts, aircraft wings, and bridge supports. The
key characteristic of fatigue is that it happens gradually, with the crack propagating
incrementally with each load cycle until the remaining cross-sectional area can no longer support
the load, leading to sudden failure.
Q2 Set A
LMP of a material is given below. Find the Rupture time for the material at 100 MPa stress if
exposed to 800K. Also find the reduction in life if the stress level is increased to 200MPa. (7
Marks)

Laron-Miller parameter is;

Comparing both equations;

Given,

Using graph, at 50 MPa, we can find the Larson-Miller parameter as;

Q2 Set B
LMP of a material is given below. Find the Rupture time for the material at 50 MPa stress if
exposed to 900K. Also find the reduction in life if the stress level is increased to 100MPa. (7
Marks)
Solve similar to Set A

Q2 Set C
LMP of a material is given below. Find the Rupture time for the material at 200 MPa stress if
exposed to 600K. Also find the reduction in life if the stress level is increased to 600MPa. (7
Marks)

Solve similar to Set A

Q3 Set A
Load history of A fatigue loaded component made of 2014-T6 Aluminium is given
below. Find the residual life of the component as per the table if it is subjected to
1000rpm. (6 Marks)

Sl.No. Stress Amplitude Number of cycles

MPa
1 300 100
2 200 100000
3 150 ?
8000000 cycles/1000 rotations/min or cycles/minute = 8000 minutes
Q3 Set B
Load history of A fatigue loaded component made of 2014-T6 Aluminium is given
below. Find the residual life of the component as per the table if it is subjected to
2000rpm.

Sl.No. Stress Amplitude Number of cycles

MPa
1 250 10000
2 200 100000
3 150 ?

Solve similar to Set A

Q3 Set C
Load history of A fatigue loaded component made of 2014-T6 Aluminium is given
below. Find the residual life of the component as per the table if it is subjected to
3000rpm. (6 Marks)

Sl.No. Stress Amplitude Number of cycles

MPa
1 250 20000
2 150 200000
3 100 ?
Solve similar to Set A

Q.4 Set. (A) [7 Marks]

A cantilever beam contains a through-thickness crack. The beam is loaded by a system of forces
as shown in the figure. Determine at what value of P failure may be expected. Numerical data:
crack length (2a) = 0.04m, beam thickness t = 0.035m, plate width b =0.09m, d=0.07m, l=3.2m,
yield strength σy =600MPa, and fracture toughness KIc =50 MPa m1/2. The geometrical factor can
be taken as 1.12 for fracture toughness calculation. Also, check if the given system plate
thickness and crack size satisfy the condition for plain strain fracture toughness test.

P is the applied load, a is the crack length, t is the beam thickness.

Given data: Crack length (2a) = 0.04 m, Beam thickness (t) = 0.035 m, Plate width (b) =
0.09 m, Depth (d) = 0.07 m, Length (l) = 3.2 m, Yield strength (σ_y) = 600 MPa,
Fracture toughness (K_Ic) = 50 MPa√m, Geometrical factor (Y) = 1.12.
K_I =P* 91.32

Compare K_I with K_Ic:

If K_I is greater than or equal to K_Ic, failure may be expected. If K_I is less than K_Ic,
failure is not expected.

K_Ic=50

K_I =P* 91.32

K_I>=K_Ic (FAILURE)

P* 91.32>=50

P>=50/91.32

P>=0.547

Explanation:
Compare K_I with K_Ic: If K_I is greater than or equal to K_Ic, failure may be expected.
If K_I is less than K_Ic, failure is not expected.
Q.4 Set. (B) [7 Marks]
A cantilever beam contains a through-thickness crack. The beam is loaded by a system of forces
as shown in the figure. Determine at what value of P failure may be expected. Numerical data:
crack length (2a) = 0.05m, beam thickness t = 0.03m, plate width b =0.08m, d=0.06m, l=3.2m,
yield strength σy =600MPa, and fracture toughness KIc =50 MPa m1/2. The geometrical factor can
be taken as 1.12 for fracture toughness calculation. Also, check if the given system plate
thickness and crack size satisfy the condition for plain strain fracture toughness test.

Solve similar to Set A

Q.4 Set. (C) [7 Marks]

A cantilever beam contains a through-thickness crack. The beam is loaded by a system of forces
as shown in the figure. Determine at what value of P failure may be expected. Numerical data:
crack length (2a) = 0.06m, beam thickness t = 0.03m, plate width b =0.09m, d=0.06m, l=3.2m,
yield strength σy =600MPa, and fracture toughness KIc =50 MPa m1/2. The geometrical factor can
be taken as 1.12 for fracture toughness calculation. Also, check if the given system plate
thickness and crack size satisfy the condition for plain strain fracture toughness test.

Solve similar to Set A

Q.5 Set. (A) [8 Marks]

A cylindrical tensile specimen with an initial gage length of 50 mm and initial diameter of 12.5
mm is tested in a universal testing machine as per ASTM specification. The gage length after
fracture was observed to be 65 mm and a minimum diameter at fracture was obtained as 10 mm.
The measured load corresponding to the 0.2% offset yield is 100 kN, that at the point of the onset
of necking is 130 kN and that at the point of fracture is 110 kN, determine the following:

(a) 0.2% offset yield strength and ultimate tensile strength

(b) Fracture strength and applied true fracture strength.
(c) Elongation and true strain at fracture.
(d) Reduction of area and true reduction of area at fracture.
Q.5 Set. (B) [8 Marks]
A cylindrical tensile specimen with an initial gage length of 100 mm and initial diameter of 25
mm is tested in a universal testing machine as per ASTM specification. The gage length after
fracture was observed to be 125 mm and a minimum diameter at fracture was obtained as 21
mm. The measured load corresponding to the 0.2% offset yield is 150 kN, that at the point of the
onset of necking is 210 kN and that at the point of fracture is 175 kN, determine the following:

(a) 0.2% offset yield strength and ultimate tensile strength

(b) Fracture strength and applied true fracture strength.
(c) Elongation and true strain at fracture.
(d) Reduction of area and true reduction of area at fracture.

Solve similar to Set A

Q.5 Set. (C) [8 Marks]

A cylindrical tensile specimen with an initial gage length of 80 mm and initial diameter of 25
mm is tested in a universal testing machine as per ASTM specification. The gage length after
fracture was observed to be 100 mm and a minimum diameter at fracture was obtained as 21
mm. The measured load corresponding to the 0.2% offset yield is 160 kN, that at the point of the
onset of necking is 200 kN and that at the point of fracture is 170 kN, determine the following:

(a) 0.2% offset yield strength and ultimate tensile strength

(b) Fracture strength and applied true fracture strength.
(c) Elongation and true strain at fracture.
(d) Reduction of area and true reduction of area at fracture.

Solve similar to Set A

Q.6 Set. (A) [5 Marks]
A certain material has a Brinell hardness of 157 BHN. Two Brinell hardness tests were
conducted on this material, one using a 10mm dia indenter and 3000kg load and another with a 7
mm dia indenter and 1470 kg load. Calculate the diameter of indentation in both cases and
comment on the results.
 Now, let's comment on the results:

The results show that the diameter of indentation is smaller in Case 2 (2.812 mm) than in
Case 1 (3.343 mm). This indicates that the material is harder to deform under the applied
load in Case 2.

The smaller diameter of indentation in Case 2 suggests that the material has a higher
resistance to indentation. It can be inferred that the material is relatively harder when a
smaller indenter diameter and lower load are used.

In comparison, when a larger indenter diameter and higher load are applied (Case 1), the
material is more easily deformed, resulting in a larger diameter of indentation.

Overall, the results demonstrate that the Brinell hardness is influenced by both the applied load
and the diameter of the indenter, with smaller indentations indicating greater hardness.

Q.6 Set. (B) [5 Marks]

Vickers hardness test was conducted on a certain material using 1000 g load. The observed
Vickers hardness is 40 MPa. Calculate the size of the square indentation observed in this test.
Why Brinell hardness test is restricted for low and medium hardness material whereas Vickers
hardness test can be suitable for all materials?

Given Data:
Load (L): 1000 g (which is equivalent to 1 kgf, since 1 kgf = 1000 g)
Vickers Hardness (HV): 40 MPa
Vickers Hardness Test Formula:
The Vickers hardness test formula is given by:

where:

HV = Vickers hardness number

L = Load applied during the test in kgf
d = Diagonal of the square indentation in mm
1.8544 = Geometric constant for the diamond pyramid indenter
Note: Load (L) is converted to kgf, so 1000 g becomes 1 kgf.

Conclusion:
The diagonal length of the square indentation observed in this Vickers hardness test is
approximately 0.2153 mm.
Q.6 Set. (C) [5 Marks]

How do you differentiate an oxidation and reduction electrochemical reactions. With respect to
corrosion, briefly mention where these reactions will occur?
A piece of corroded metal alloy plate (density=4.5 g/cm3) was found submerged in ocean. It was
estimated that the original area of the plate was 800 cm2 and that approximately 7.6 kg had
corroded away during the submersion period of 5.3 years. Estimate the corrosion penetration rate
for the metal plate.
So the final answer is that,

Based on the given info, you should not try for the pot of the gold at the end of the
rainbow. •TRUE